- Wheel Tractor-Scraper:
- 615 (S/N: 46Z1-UP; 47Z1-UP)
- 615C Series II (S/N: 2XG1-897,898-UP)
- 615C (S/N: 5TF1-UP)
- 615C Series II (S/N: 2XG1-897,898-UP)
Introduction
| Revision | Summary of Changes in REHS3186 |
| 02 | Standardized. |
| 01 | Added new Introduction and Canceled Part Numbers section |
© 2015 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.
This special instruction contains the necessary information that is required to bench test- specific transmission arrangements. Refer to Table 2 for the correct arrangements. Bench testing the transmission ensures correct assembly and operation of the component. Rotating a transmission provides the most conclusive evaluation. This allows the dealer to ensure that the transmission will operate properly in the machine. The specifications in this guideline are specific to bench testing the component. Every effort has been made in order to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This guideline must be used with the latest technical information that is available from Caterpillar.
For questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. In order to address an urgent issue, use the following resources in order to communicate your request to Caterpillar Repair Process Engineering:
- Cat Dealer Techinical Communicator
- Dealer Solution Network
- Cat Technical Representative
- Knowledge Network
| Machine Model | Transmission Arrangement |
| 615 | 8P-7900 |
| 615C | 8P-7900 |
Canceled Part Numbers and Replaced Part Numbers
This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.
Important Safety Information
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| Illustration 1 | g02139237 |
Follow all safety warnings. Most accidents that involve product operation, maintenance, or repair are caused by failure to observe safety warnings. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. Personnel must be properly trained in order to perform maintenance, repair, or operate any machine. Safety precautions and warnings are provided this instruction and on Caterpillar products. These warnings should be observed before performing any procedures. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are not all inclusive.
The hazards are identified by the "Safety Alert Symbol" which is followed by a "Signal Word" such as "DANGER", "WARNING, or" "CAUTION". The "WARNING" Safety Alert Symbol is shown in illustration below.
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| Illustration 2 | g00008666 |
This safety alert symbol means:
Pay Attention!
Become Alert!
Your Safety is Involved.
The message that appears under the safety alert symbol explains the hazard.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.
The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.
Collecting The Test Data
Since conditions vary for each test bench, use the data that is collected from your test bench. The collected data is used to compare test results. The data should be collected and maintained by the operator.
Data from each transmission arrangement is collected and stored. Averages from each transmission arrangement are often used in order to compare values on portions of transmission tests. Always compare data that is collected from the same transmission arrangement that is being tested. Averages for the last 20 transmission arrangements should be maintained.
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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. |
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Personal injury or death can result from not following the proper procedures. To avoid the possibility of injury or death, follow the established procedure. |
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Tools Needed
Note: Pressures will be sensitive to tooling setup. The diameter of the hose, the diameter of a fitting, and additional filtering can affect pressure. The required tools that are listed in Table 3 were used to develop this test procedure.
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 1U-9584 | Rail As | 1 |
| FT-1078 | Support | 1 | |
| 1U-9585 | Block Group | 1 | |
| B | FT-1665 | Adapter (Input Drive) | 1 |
| C | 1U-9722 | Ratcheting Turnbuckle | 3 |
| D | 8C-9024 | Nipple (Quick Disconnect) | 1 |
| 9U-7446 | Adapter | 1 | |
| 1U-8304 | Fitting | 1 | |
| 1P-4577 | Split Flange | 2 | |
| E | 8C-9024 | Nipple (Quick Disconnect) | 1 |
| 1U-8297 | Fitting | 1 | |
| 1P-4577 | Split Flange | 1 | |
| F | 8C-9024 | Nipple (Quick Disconnect) | 1 |
| 9U-7446 | Adapter | 1 | |
| 1U-8301 | Fitting | 1 | |
| 120-6843 | Ball Valve | 1 | |
| 8C-9025 | Coupler (Quick Disconnect) | 1 | |
| 7X-7646 | Nipple (Quick Disconnect) | 1 | |
| 6B-9081 | Bushing (Reducing) | 2 | |
| 7F-6654 | Nipple (Pipe) | 2 | |
| G | 4L-4454 | Air Pressure Regulator Valve | 1 |
| 3B-7740 | Nipple (Pipe) | 1 | |
| 6B-5072 | Bushing (Reducing) | 2 | |
| 5H-7826 | Nipple (Pipe) | 1 | |
| 3B-7719 | Coupling (Reducing) | 1 | |
| 3B-6553 | Elbow | 1 | |
| 7S-8887 | Nipple (Quick Disconnect) | 1 | |
| 3P-1556 | Gauge | 1 | |
| H | 7S-8887 | Nipple (Quick Disconnect) | 1 |
| 5P-3501 | Adapter | 1 | |
| 3J-1907 | Seal | 1 | |
| J | 7S-8887 | Nipple (Quick Disconnect) | 1 |
| 5P-3501 | Adapter | 1 | |
| 3J-1907 | Seal | 1 | |
| K | 7S-8887 | Nipple (Quick Disconnect) | 1 |
| 5P-3501 | Adapter | 1 | |
| 3J-1907 | Seal | 1 | |
| L | 7S-8887 | Nipple (Quick Disconnect) | 1 |
| 5P-3501 | Adapter | 1 | |
| 3J-1907 | Seal | 1 | |
| M | 9S-4183 | Plug | 1 |
| 3D-2824 | Seal | 1 | |
| N | 9S-4185 | Plug | 1 |
| 3K-0360 | Seal | 1 | |
| P | 7S-8890 | Nipple (Quick Disconnect) | 1 |
| 3B-7282 | Nipple (Pipe) | 1 | |
| Q | 7S-8890 | Nipple (Quick Disconnect) | 1 |
| 3B-7282 | Nipple (Pipe) | 1 | |
| R | 7S-8890 | Nipple (Quick Disconnect) | 1 |
| 3B-7282 | Nipple (Pipe) | 1 | |
| S | FT-1679 | Test Cover | 1 |
FT Drawings
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| Illustration 3 | g03887974 |
FT-1078 All Dimensions are in millimeters | |
 | |
| Illustration 4 | g03823820 |
FT-1665 (A) 44.45 mm (1.75 inch) (B) 12.7 mm (0.5 inch) (C) 31.75 mm (1.25 inch) (D) Ø 149.23 mm (5.875 inch) (E) Ø 140.45 mm (5.53 inch) (F) 94.28 mm (3.71 inch) (G) 47.14 mm (1.86 inch) (H) 94.28 mm (3.71 inch) (I) 47.14 mm (1.86 inch) (J) 42.88 mm (1.69 inch) (K) 21.44 mm (0.844 inch) (L) Ø 8.2 mm (0.3 inch), 25.4 mm (1.0 inch) Deep, 3/8-12-2B THD (M) Ø 10.5 mm (0.4 inch), Ø 22.2 mm (0.874 inch) Bore, 14 mm (0.55 inch) Deep (N) Ø 92.0 mm (3.622 inch) (O) 57.15 mm (2.25 inch) (P) 114.3 mm (4.5 inch) | |
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| Illustration 5 | g03887994 |
FT-1679 | |
Installation Procedure
- Install Tooling (A) .
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| Illustration 6 | g01257680 |
Typical Example | |
- Use a hoist to install the transmission on the test bench. The weight of the transmission is 915.3 kg (2018 lb).
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| Illustration 7 | g03887013 |
Typical Example | |
- Install Tooling (B) .
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| Illustration 8 | g01257694 |
Typical Example | |
- Align the transmission with the input drive shaft.
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| Illustration 9 | g01257695 |
Typical Example | |
- Connect the input shaft to Tooling (B) .
- Install the drive shaft guard.
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| Illustration 10 | g01257696 |
Typical Example | |
- Tighten all four castle nuts and jack bolts.
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| Illustration 11 | g03802221 |
- Install Tooling (C) to the input end of the transmission.
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| Illustration 12 | g01257700 |
Typical Example | |
- Install Tooling (C) to the output end of the transmission.
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| Illustration 13 | g01257708 |
- Remove Cover (1) to allow oil to drain out of the transmission.
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| Illustration 14 | g01257723 |
Typical Example | |
- Install Tooling (D) .
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| Illustration 15 | g01257746 |
- Install Tooling (E) .
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| Illustration 16 | g01257764 |
- Install Tooling (F) .
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| Illustration 17 | g01257760 |
- Install Tooling (G) .
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| Illustration 18 | g01257770 |
- Install Tooling (H) .
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| Illustration 19 | g01257775 |
- Install Tooling (J) .
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| Illustration 20 | g01257783 |
- Install Tooling (K) .
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| Illustration 21 | g01257789 |
- Install Tooling (L) .
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| Illustration 22 | g01257793 |
- Install Tooling (M) .
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| Illustration 23 | g01257808 |
- Install Tooling (N) .
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| Illustration 24 | g01257811 |
- Connect hose assembly (2) from the pressurized flow meter to Tooling (D) .
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| Illustration 25 | g01257847 |
(2) Oil Supply | |
- Connect hose assembly (3) from the No. 2 flow meter outlet to Tooling (E) .
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| Illustration 26 | g01257858 |
(3) Lubrication Inlet | |
- Connect hose assembly (4) from Tooling (F) to the inlet of the No. 2 flow meter.
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| Illustration 27 | g01257862 |
(4) Lubrication Outlet | |
- Connect air supply line (5) to Tooling (G) .
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| Illustration 28 | g01257877 |
(5) Air Pressure To Lockup Clutch | |
- Connect pressure gauge (6) to Tooling (H) .
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| Illustration 29 | g01257889 |
(6) Pitot Tube Pressure | |
- Connect pressure gauge (7) to Tooling (J) .
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| Illustration 30 | g01257891 |
(7) Lubrication Pressure | |
- Connect pressure gauge (8) to Tooling (K) .
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| Illustration 31 | g01257896 |
(8) Lockup Clutch Pressure | |
- Connect pressure gauge (9) to Tooling (L) .
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| Illustration 32 | g01257899 |
(9) Signal Pressure | |
- Install Tooling (P) .
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| Illustration 33 | g01257813 |
- Install Tooling (Q) .
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| Illustration 34 | g01257824 |
- Install Tooling (R) .
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| Illustration 35 | g01257835 |
- Install Tooling (S) .
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| Illustration 36 | g01257839 |
- Connect pressure gauge (10) to Tooling (P) .
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| Illustration 37 | g01257905 |
(10) Speed Clutch And Initial Pressure "P1" | |
- Connect pressure gauge (11) to Tooling (Q) .
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| Illustration 38 | g01257908 |
(11) Directional Clutch Pressure "P2" | |
- Connect pressure gauge (12) to Tooling (R) .
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| Illustration 39 | g01257917 |
(12) Torque Converter Inlet Pressure "P3" | |
Test Procedure
Start Checks
- If you are using SAE 10W oil, warm the oil to 50 °C (125 °F). If you are using Mobil DTE11 oil, warm the oil to 34 °C (95 °F). Maintain this temperature for the duration of the test.
Note: Refer to Testing and Adjusting, SENR2392, "Power Shift Transmission" for the correct adjusting procedures.
- Adjust input flow to 34 ± 4 L/min (9 ± 1 US gpm).
- With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 850 ± 10 rpm.
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| Illustration 40 | g02720621 |
- Shift the transmission through all gears to eliminate air from the transmission controls.
- Confirm the correct clutch engagement with Table 4.
Show/hide table
Table 4 Clutch Engagement Check Gear Cl 1 Cl 2 Cl 3 Cl 4 Cl 5 Cl 6 N X R X X F1 X X F2 X X F3 X X F4 X X F5 X X F6 X X
- Stop the input rotation.
Initial Pressure
- Remove the load piston plug from the top of the controls.
- Shift the transmission to NEUTRAL.
- Adjust the input rotation to 850 ± 10 rpm.
- Adjust input flow to 34 ± 4 L/min (9 ± 1 US gpm).
- The initial "P1" clutch pressure must be 530 ± 35 kPa (77 ± 5 psi).
- Record the value in Table 7.
- Stop the input rotation.
- Install the load piston plug.
Pressure Differential Valve
- Shift the transmission into FORWARD 6.
- Adjust the input rotation to 850 ± 10 rpm.
- Adjust input flow to 34 ± 4 L/min (9 ± 1 US gpm).
- The "P2" directional clutch pressure must remain at zero.
- Adjust input speed to 2200 ± 10 rpm.
- Adjust input flow to 95 ± 4 L/min (25 ± 1 US gpm).
- The "P2" directional clutch pressure must remain at zero.
- Shift the transmission to NEUTRAL.
- Shift the transmission into any gear range that is not NEUTRAL.
- The "P2" directional clutch pressure must rise to normal pressure.
- Record the values in Table 8.
Torque Converter Inlet Relief Valve
- Adjust the input rotation to 850 ± 10 rpm.
- Adjust input flow to 34 ± 4 L/min (9 ± 1 US gpm).
- Shift the transmission to any position that is not NEUTRAL.
- Use Tooling (F) to momentarily block the flow at the torque converter outlet.
- The "P3" torque converter inlet pressure must be 931 ± 83 kPa (135 ± 12 psi).
- Open the lube flow.
- Record the value in Table 9.
Lube Circuit
- Shift the transmission to FORWARD 2.
- Adjust the input rotation until the lube flow is 42 ± 4 L/min (11 ± 1 US gpm). Maintain this flow during this check.
- The lubrication pressure must be 14 kPa (2 psi).
- Record the value in Table 10.
Lockup Clutch
- Shift the transmission to NEUTRAL.
- Adjust input speed to 850 ± 30 rpm.
- Adjust input flow to 95 ± 4 L/min (25 ± 1 US gpm).
- Lockup clutch pressure must be zero.
- Gradually adjust input speed to 1480 ± 15 rpm.
- Lockup clutch pressure must increase to620 ± 103 kPa (90 ± 15 psi) less than "P1".
Note: If necessary, adjust the lockup clutch valve to get the correct shift point. Refer to Testing and Adjusting, SENR2392, "Power Shift Transmission" for the correct adjusting procedures.
- Gradually adjust input speed to 850 ± 30 rpm.
- Lockup clutch pressure must drop to zero at 1350 ± 35 rpm.
- Supply air pressure through Tooling (F) at 483 ± 69 kPa (70 ± 10 psi).
- Adjust input speed to 2200 ± 10 rpm.
- Lockup clutch pressure must remain at zero.
- Relieve air pressure through Tooling (F) .
- Lockup clutch pressure must return to 550 ± 35 kPa (80 ± 5 psi).
Contamination Control
- Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 16/13.
- Record the results in Table 11.
- Remove the transmission from the test bench if the test bench oil supply is within specifications.
Transmission Bench Test Data Sheet
| CATERPILLAR | Transmission Bench Test Data Sheet | Test Date:_______ |
| Model:_______ | ||
| Work Order:_______ | Serial No.:_______ | |
Specifications
| Specifications | ||
| Description | High Idle | Low Idle |
| Input Speed | 2200 ± 10 rpm | 850 ± 10 rpm |
| Input Flow | 95 ± 4 L/min (25 ± 1 US gpm) |
34 ± 4 L/min (9 ± 1 US gpm) |
| Minimum Lube Flow | 73 L/min (19 US gpm) |
11 L/min (3 US gpm) |
| Pressures | ||
| "P1" Initial (1) | - | 530 ± 35 kPa (77 ± 5 psi) |
| "P1" Pressure | 2550 ± 140 kPa (370 ± 20 psi) |
2205 kPa (320 psi) Minimum |
| "P2" Pressure | P1 - 380 ± 55 kPa (P1 - 55 ± 8 psi) |
P1 - 380 ± 55 kPa (P1 - 55 ± 8 psi) |
| "P3" Pressure | - | 931 ± 83 kPa (135 ± 12 psi) (2) |
| Lockup Clutch Pressure | P1-620 ± 100 kPa (P1-90 ± 15 psi) |
0 kPa (0 psi) |
| ( 1 ) | The load piston plug is removed and the transmission is in NEUTRAL. |
| ( 2 ) | The torque converter oil flow is restricted. |
Initial Pressure Check
| "P1" Clutch Pressure | Input Speed (850 ± 30 rpm) Gear Range NEUTRAL Removed Load Piston Plug |
_______kPa _______(psi) |
Pressure Differential Valve
| "P2" Directional Clutch Pressure | Input Speed (850 ± 30 rpm) |
| Gear Range FORWARD 6 | _______kPa _______(psi) |
| Any Gear Range Except NEUTRAL | _______kPa _______(psi) |
Torque Converter Inlet Relief Valve
| "P3" Torque Converter Inlet Pressure | Input Speed (850 ± 30 rpm) Any Gear Range ExceptNEUTRAL Restricted Torque Converter Outlet |
_______kPa _______(psi) |
|||
Lube Circuit Check
| Lube Pressure | Gear Range FORWARD 2 Input Flow 42 ± 4 L/min (11 ± 1 US gpm) |
_______kPa _______(psi) |
|
Contamination Control
| ISO Particle Count | Sample the test bench oil supply. |
________/________Particle Count |
| ______________________________________ Technician |
______________________________________ Supervisor |